Motor Wire Connection Terminal Folding Method
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Solution Overview
Problem
Conventional methods for connecting wires and leads in motors require multiple connection terminals of different sizes, leading to unstable connections, increased material costs, and complex facility investments due to the need for various crimping machines and excessive wire diameters that do not match current carrying capacities.
Innovation Solution
A method involving a connection terminal with a crimping part that folds the wire one or more times to increase the cross-section area, allowing for a single-size terminal to securely connect wires and leads of different diameters, ensuring a predetermined amount of distortion and stable electrical and mechanical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple connection terminals of different sizes are used to match wire diameters, then connection stability is improved, but device complexity and material costs increase
Solution Approach 1:
The patent applies universality by designing a single connection terminal that can accommodate multiple wire diameters through its folding structure. The terminal body is configured with a universal crimping part that can securely connect wires of different sizes by folding the wire multiple times, eliminating the need for multiple specialized terminals of different sizes.
Solution Approach 2:
The patent applies the nested doll principle by folding the wire one or more times within the connection terminal. The folded wire structure allows smaller wire sections to be nested within larger terminal dimensions, enabling a single terminal size to effectively connect wires of various diameters through multiple folding layers.
2Manufacturing precision
If multiple crimping machines for different terminal sizes are invested in, then manufacturing precision is improved, but facility investment costs increase
Solution Approach 1:
The patent enables a single crimping machine to perform crimping operations for all wire sizes by working with the universal connection terminal. The terminal's folding structure allows one crimping machine to achieve precise connections for wires of different diameters, eliminating the need to invest in multiple specialized crimping machines.
3Reliability
If wire diameter is increased to match terminal size, then connection stability is improved, but material costs and current carrying efficiency worsen
Solution Approach 1:
The patent applies nesting by folding the wire multiple times within the terminal, allowing thin wires to occupy the space of larger terminals through nested folding layers. This enables connection stability without requiring excessive wire diameter, as the folded structure provides sufficient contact area and mechanical strength within the terminal.
4Device complexity
If a single-size connection terminal is used for all wires, then device complexity is reduced, but connection stability deteriorates due to gaps
Solution Approach 1:
The patent resolves the gap problem by folding the wire one or more times within the single-size terminal. The folded wire structure fills the space between the wire and terminal walls, eliminating gaps that would otherwise form with thin wires in large terminals. This nested folding approach ensures stable electrical and mechanical connections without requiring multiple terminal sizes.
Solution Approach 2:
The patent applies dimensionality change by transforming the wire from a straight linear form to a folded multi-dimensional structure within the terminal. By folding the wire multiple times, the solution creates additional contact points and distributes the connection across multiple dimensions, ensuring stable connections in a single-size terminal regardless of wire diameter.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces facility investments, simplifies motor production management, and minimizes material costs by enabling proper crimping of wires with varying diameters using a single-size connection terminal, aligning with current carrying capacities rather than terminal specifications.
Implementation Method 1
a distorted area is formed in wire 20a and core wire 22a. When a predetermined amount of distortion is applied to wire 20a and core wire 22a, they are electrically and mechanically connected with each other
Implementation Method 2
the folded folding part and the connecting part are crimped with each other at the crimping part
Data Source
AI summary
According to the method for connecting motor wire of the present invention, wire as a first wire having folding part is connected to lead as a first lead or a second wire, each having connecting part, with connection terminal having crimping part. After folding part is folded one or more times, folding part and connecting part are crimped at crimping part.